water MAZDA 626 1987 Repair Manual

3A TROUBLESHOOTING GUIDE i
SPECIFICATIONS
^Engine model
Item ^__
FE-DOHC
FE 8-valve,
F8, F6...except
Middle East
.General
FE 12-valve
FE 8-valve F8, F6...only Middle East General

Cooling system Water cooled, forced circulation
Coolant capacity liters (US qt, Imp qt)
With heater 7.5 (7.9, 6.6) Coolant capacity liters (US qt, Imp qt) Without heater 7.0 (7.4, 6.2)
Water pump Type Centrifugal, timing belt driven Water pump
Water seal Unified seal
Thermostat
Type Wax, 2-stage Wax
Thermostat
Opening temperature °C(°F) Sub
.
83.5-86.5 (182-188) Main: 86.5-89.5 (188-193) 86.5-89.5 (188-193) 80.5-83.5 (177-182) Thermostat
Full-open temperature °C(°F) 100 (212) 95 (203)
Thermostat
Full-open lift
mm
(in) Sub: 1.5 (0.06) min.
Main: 8.0 (0.31) min. 8.5 (0.33) min.
Radiator
Type Corrugated
Radiator Cap valve opening pressure
kPa (kg/cm2, psi) 74-103 (0.75-1.05, 11-15)
Cooling
fan

Capacity
W

MTX 80
Cooling
fan

Capacity
W
ATX 120
Cooling
fan
Number
of
blade 4 Cooling
fan

Outer diameter
of
blade
mm
(in) MTX 320 (12.6)
Cooling
fan

Outer diameter
of
blade
mm
(in)
ATX 340 (13.4)

76G03A-003
TROUBLESHOOTING GUIDE
Problem Possible Cause Remedy Page
Overheating
Insufficient coolant Add 3A—
5

Coolant leakage Repair
—

Radiator fins clogged Clean 3A—
7

Radiator cap malfunction Replace 3A-
6

Cooling fan malfunction Repair 3A-12 Thermostat malfunction Replace 3 A-11
Water passage clogged Clean 3A—
5

Water
DumD
malfunction ReDair
or
replace 3A-
8
Corrosion
Impurities
in
coolant Replace 3A-
5
76G03A-004
3A—4

3A RADIATOR CAP
J I

V
J* J Q lanana
86U03X-028
86U03X-007
86U03X-008
3. Set the heater control switch to the maximum heat
position.
4. Flush the cooling system with water until all traces
of color are gone, then let the system drain com-
pletely.
5. Fill with the proper mixture and amount of ethy-
lene glycol-based coolant.
Caution
a) Do not use alcohol- or methanol-based
coolant.
b) Use only soft (demineralized) water in the
coolant mixture.
Anti-freeze solution mixture percentage

Protection Volume percentage Gravity
at

20°C (68°F) Protection Solution Water
Gravity
at

20°C (68°F)
Above -16°C (3°F) 35 65 1.054
Above -26°C (-15°F) 45 55 1.066
Above -40°C (-40°F) 55 45 1.078

6. Run the engine at idle with the radiator cap re-
moved. Let any air bleed from the system, and add
more coolant.
7. Install the radiator cap, and inspect all connections
for leakage.
RADIATOR CAP
INSPECTION
Radiator Cap Valve
1. Remove foreign material (such as water residue)
from between the radiator cap valve and the valve
seat.
2. Attach the radiator cap to a tester with the SST.
Apply pressure gradually to 74—103 kPa
(0.75—1.05 kg/cm2, 11—15 psi).
3. Wait about 10 seconds; then check that the pres-
sure has not decreased.
Negative Pressure Valve
1. Pull the negative-pressure valve to open it. Check
that it closes completely when released.
2. Check for damage on the contact surfaces, and
for cracked or deformed seal packing.
3. Replace the radiator cap if necessary.
86U03X-009
3A—6

RADIATOR 3A
RADIATOR
REMOVAL AND INSTALLATION
1. Drain the engine coolant.
2. Remove in the sequence shown in the figure.
3. Install in the reverse order of removal.
76G03A-005
5. Upper and lower radiator hose
6. Cooling fan and radiator assembly
7. Cooling fan
INSPECTION
Check the following points. Repair or replace if
necessary.
1. Cracks, damage, or water leakage
2. Bent fins (Repair with a screwdriver)
3. Distorted or bent radiator inlet.
Note
a) Position the hose clamp in the original location on the hose.
b) Squeeze the clamp lightly with large pliers to ensure a good fit. 86U03X-010
1. Coolant reservoir hose
2. ATF hose (ATX)
3. Water thermo switch connector
4. Cooling fan connector
86U03X-012
3A-7

3A WATER PUMP
WATER PUMP
REMOVAL
1. Disconnect the negative battery cable.
2. Turn the crankshaft so that the No. 1 cylinder is at TDC of compression.
3. Drain the engine coolant.
4. Remove in the sequence shown in the figure.
1. Timing belt (Refer to Section 1B) 4. Idler pulley
2. Camshaft pulley (Refer to Section 1B) 5. Water pump
3. Seal plate 6. O-ring
3A—8

WATER PUMP 3A
SOHC
19—25 N m (1.9—2.6 m-kg, 14—19 ft-lb)
37—52 N m (3.8—5.3 m-kg, 27—38 ft-lb)
1. Timing belt (Refer to Section 1A)
2. Idler pulley
3. Water pump
4. O-ring
76G03A-007
3A-9

3A WATER PUMP
INSPECTION
Check the following. Replace the pump if necessary.
1. Cracks or damage
2. Abnormal noise, bearing sticking or loose.
86U03X-014
INSTALLATION
Install in the reverse order of removal referring to the
installation note.
Installation Note
Rubber seal
Install the rubber seals on the water pump.
76G03A-017
86U03X-016
Water pump
1. Remove any gasket fragments, dirt, or oil from the
contact surfaces.
2. Install a new O-ring on the water pump.
3. Install the water pump.
Tightening torque:
19—25 Nm (1.9—2.6 m-kg, 14—19 ft-lb)
Note
To prevent dropping the O-ring when install-
ing, put silicon sealant in the O-ring groove
(shaded areas) as shown. Do not apply it to
the contact surfaces.
3A—10

THERMOSTAT 3A
69G03B-010
76G03A-008
76G03A-009
THERMOSTAT
REMOVAL
1. Drain the engine coolant.
2. Remove the thermostat cover.
3. Remove the thermostat.
INSPECTION
Check the thermostat. Replace if necessary.
1. Visually check that the valve is airtight.
2. Place the thermostat and a thermometer in water.
3. Gradually heat the water and check the following:
\ Model
Item
FEDOHC
FE 8-valve F8,F6...except
Middle
East General FE 12-valve
FE 8-valve, F8,F6...only Middle East General

Initial opening
tem-
perature

Sub
valve 83.5—86.5°C (182—188°F) Main valve 86.5—89.5°C (188—193°F)
86.5—89.5°C
(188—193°F)
80.5—83.5°C (177—182°F)
Full-open
temperature 100°C (212°F) 95°C (203°F)
Full-open
lift

Sub
valve
1.5
mm
(0.06 in) min.
Main valve
8.0
mm
(0.31 in) min.
8.5
mm
(0.33
in)min.

INSTALLATION
1. Install the thermostat into the cylinder head with
jiggle pin at the top.
2. Install a new gasket with the seal print side facing
the cylinder head.
3. Install the thermostat cover.
Tightening torque:
19—30
N
m (1.9—3.1 m-kg, 14—22 ft-lb)
4. Replenish the coolant.
5. Start the engine and check for leaks.
86U03X-018
3 A-11

3A COOLING FAN
COOLING FAN
SYSTEM CIRCUIT
IG1 IG Relay
*
No.1
relay
Water thermo switch
I With A/C

CM)
Main fan
1
L..±
No.2
relay
IG2
Add.
relay ol
(M)
A/C sw.
Add fan
86U03X-019
CIRCUIT INSPECTION
1. Turn the ignition switch ON.
2. Disconnect the water thermo switch connector, and
check that the fan operates.
3. If the fan doesn't operate, check the fuse, fan re-
lay, fan motor, thermo switch and wiring harness.
76G03A-010
3 A—12

3A COOLING FAN
WATER THERMO SWITCH
1. Remove the cooling fan water thermo switch.
Note
Make sure that the ignition switch is OFF. If
not, the fan will operate when the connector
is removed.
76G03A-013
76G03A-014
Place the water thermo switch in water.
Heat the water gradually, and check for continui-
ty of the switch with an ohmmeter. Replace if
necessary.
Water thermo switch (ON OFF):
97°C (207°F)....ECE, Hong Kong, Singapore

91
°C (196°F)....General, Middle East
Install the water thermo switch and a new O-ring.
Caution
Do not use sealing tape.
3 A—14

3B
COOLING SYSTEM
(DIESEL)
OUTLINE 3B— 2
COOLANT FLOW CHART 3B— 2
SPECIFICATIONS 3B— 3
TROUBLESHOOTING GUIDE 3B— 3
COOLANT 3B— 4
INSPECTION 3B— 4
REPLACEMENT 3B— 4
RADIATOR CAP 3B— 5
INSPECTION 3B— 5
RADIATOR 3B— 6
REMOVAL AND INSTALLATION 3B— 6
INSPECTION 3B— 6
WATER PUMP 3B— 7
REMOVAL 3B— 7
INSPECTION 3B— 8
INSTALLATION 3B— 8
THERMOSTAT 3B— 9
REMOVAL 3B— 9
INSPECTION 3B— 9
INSTALLATION 3B— 9
COOLING FAN 3B—10
SYSTEM CIRCUIT 3B—10
CIRCUIT INSPECTION 3B—10
FAN MOTOR 3B—11
WATER THERMO SWITCH 3B—12
76G03B-001